Brake rotor

Abstract

The present invention is predicated upon improved brake rotors and methods of forming thereof which include tangential stiffening to reduce vibration and noise of the brake rotor.

1 ) A cast brake rotor, comprising:
 a) a pair of spaced apart plates defining an outer circumference and a rotational axis;   b) a fin pattern that is located between the spaced apart plates including:
 i) a plurality of cast fins located between the plates; and 
 ii) at least one tangentially oriented arcuate cast fin spaced apart from the plurality of cast fins and having an outer wall that extends at least 30 about the rotor. 
   
   
   
       2 ) The rotor of  claim 1 , wherein the at least one tangentially oriented arcurate cast fin has an outer wall that is spaced inwardly from the outer circumference of the rotor toward the rotational axis. 
   
   
       3 ) The rotor of  claim 1 , wherein a plurality of the cast fins are radially oriented and have a radially oriented length with respect to the rotational axis. 
   
   
       4 ) The rotor of  claim 3 , wherein the plurality of cast fins include at least two cast fins having different radial oriented lengths. 
   
   
       5 ) The rotor of  claim 3 , wherein at least one cast fine of the plurality of cast fins includes a distal end that is spaced inwardly from the outer circumference of the rotor toward the rotation axis. 
   
   
       6 ) The rotor of  claim 3 , wherein the plurality of cast fins includes at least one radially oriented fin and the at least one tangentially orientated arcurate cast fin extends to a location that is substantially juxtaposed with a distal end of at least one radially orientated fin. 
   
   
       7 ) The rotor of  claim 1 , wherein the at least one tangentially oriented arcuate cast fin has an outer wall that extends at least at least 90° about the rotor. 
   
   
       8 ) The rotor of  claim 1 , wherein the at least one tangentially oriented arcuate cast fin has an outer wall that extends at least at least 135° about the rotor. 
   
   
       9 ) The rotor of  claim 1 , wherein the at least one tangentially oriented arcuate cast fin has an outer wall that extends at least at least 180° about the rotor. 
   
   
       10 ) The rotor of  claim 1 , wherein the fin pattern includes a plurality of tangentially orientated arcuate cast fins. 
   
   
       11 ) The rotor of  claim 10 , wherein a first group of the tangentially oriented arcuate cast fins are spaced apart from each other in end to end relationship. 
   
   
       12 ) The rotor of  claim 10 , wherein a first group of the tangentially oriented arcuate cast fins are spaced apart radially inward relative to each other with respect to the rotational axis. 
   
   
       13 ) The rotor of  claim 10 , wherein the plurality of tangentially orientated arcuate cast fins extend at least 180° about the rotor. 
   
   
       14 ) The rotor of  claim 10 , wherein the plurality of tangentially orientated arcuate cast fins extend at least 270° about the rotor. 
   
   
       15 ) The rotor of  claim 10 , wherein the plurality of tangentially orientated arcuate cast fins extend about 360° about the rotor. 
   
   
       16 ) The rotor of  claim 1 , wherein the fin pattern is substantially asymmetrical about the rotational axis 
   
   
       17 ) A cast brake rotor, comprising:
 a) a pair of spaced apart plates defining an outer circumference and a rotational axis;   b) a fin pattern that is asymmetrical about the rotational axis and is located between the spaced apart plates, consisting essentially of:
 i) a plurality of radially aligned cast fins located between the plates; and 
 ii) an odd number of tangentially oriented arcuate cast fins having an outer wall that extends at least 30° about the rotor. 
   
   
   
       18 ) The rotor of  claim 17 , wherein the tangentially oriented arcurate cast fin has an outer wall that is spaced inwardly from the outer circumference of the rotor toward the rotational axis. 
   
   
       19 ) The rotor of  claim 17 , wherein the at least one of the tangentially orientated arcurate cast fin extends to a location that is substantially juxtaposed with a distal end of at least one radially orientated fin. 
   
   
       20 ) The rotor of  claim 17 , wherein the tangentially oriented arcuate cast fin has an outer wall that extends at least at least 90° about the rotor. 
   
   
       21 ) The rotor of  claim 17 , wherein the tangentially oriented arcuate cast fin has an outer wall that extends at least at least 135° about the rotor. 
   
   
       21 ) The rotor of  claim 1 , wherein the fin pattern includes a plurality of tangentially orientated arcuate cast fins. 
   
   
       22 ) The rotor of  claim 21 , wherein a first group of the tangentially oriented arcuate cast fins are spaced apart from each other in end to end relationship. 
   
   
       23 ) The rotor of  claim 21 , wherein a first group of the tangentially oriented arcuate cast fins are spaced apart radially inward relative to each other with respect to the rotational axis. 
   
   
       24 ) The rotor of  claim 21 , wherein the plurality of tangentially orientated arcuate cast fins extend at least 180° about the rotor. 
   
   
       25 ) The rotor of  claim 21 , wherein the plurality of tangentially orientated arcuate cast fins extend at least 270° about the rotor.